White Paper Relief Load Calculations HYSYS

aspenONE Engineering Safety Analysis Environment
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Equations and example benchmark calculations for emergency

scenario required relief loads
V8.8: Control Valve Failure, Heat Exchanger Tube Rupture, and Fire
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Craig Powers, Principal Software Developer, Aspen Technology, Inc.
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EQUATIONS AND EXAMPLE BENCHMARK CALCULATIONS FOR

EMERGENCY SCENARIO REQUIRED RELIEF LOADS
1. Control Valve Failure
For a control valve failure scenario, the required relief load is the maximum flow through the
control valve at full open. API Standard 521 allows that credit for normal minimum flow may be
taken under certain circumstances. [1]
a. PSV Plus Vapor equations

The critical pressure drop for gas or vapor flow across a control valve is defined as
∆𝑃∗ = 0.5𝐶𝑓 2 𝑃1 (Eq. 1)
where P1 is the upstream pressure in psia, P is the critical limit in psi, and Cf is a characteristic
*
parameter of the control valve.

If the pressure drop across the control valve exceeds the critical limit, then the mass flow rate
through the valve is given by
𝑤 = 2.8𝐶𝑓 𝑃1 𝐶𝑣 √𝑆𝐺 ⁄𝑍 (Eq. 2)
Otherwise, the mass flow rate through the valve is given by
∆𝑃∗ (𝑃𝑟 + 𝑃1 )𝑆𝐺

𝑤 = 3.22𝐶𝑣 √ (Eq. 3)
𝑍
where Pr is the downstream (relieving) pressure in psia, SG is the specific gravity relative to air
at upstream conditions, Z is the compressibility of the stream at upstream conditions, and Cv is
a characteristic parameter of the control valve.
The specific gravity may be calculated as
𝑀 520
𝑆𝐺 = × (Eq. 4)
29 𝑇𝑟 + 460
where M is the molecular weight and Tr is the upstream temperature in °F.
b. PSV Plus Vapor Example with Unchoked Flow

The example is based on the following conditions:
Composition: 40% isobutane, 45% isopentane, 15% n-hexane using the HYSYS SRK
package for physical properties
Upstream conditions: 320 psia / 320 F
Normal flowrate: 9,000 lb/h
Relief pressure: 260 psig set pressure + 10% allowable overpressure = 286 psig
Control Valve: Cv = 20.0, Cf = 0.75
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Figure 1. Subcritical vapor control valve case calculated in Aspen HYSYS using PSV Plus equations
Setting up a stream in HYSYS at the upstream conditions will yield the following properties:
M = 68.64
Z = 0.68
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The critical pressure drop may be calculated using (Eq. 1) as

∆𝑃∗ = 0.5(0.75)2 320 = 90 psi
The pressure drop across the valve at relieving conditions is only 19.3 psi, so the flow is
subcritical.
The specific gravity may be calculated using (Eq. 4) as
68.64 520
𝑆𝐺 = × = 1.578
29 320 + 460
The control valve capacity at relief conditions is calculated using (Eq. 3) as
19.3(286 + 14.7 + 320)1.578

𝑤 = 3.22(20)√ = 10737 lb/h
0.68
Subtracting the normal flowrate of 9,000 lb/h gives a required relief load of 1,737 lb/h.
The results calculated above are compared to results obtained in Aspen HYSYS in Table 1.
Table 1. Comparison of Example Calculation and Aspen HYSYS Calculation for Control Valve Failure with
Subcritical Vapor Flow
Variable Units Example Aspen HYSYS

Calculation
Inlet Pressure (P1) 320 psia 305.3 psig
Normal Flow to Process lb/h 9,000 9,000
Control Valve CV (CV) 20 20.00
Critical Flow Factor (Cf) 0.75 0.7500
Molecular Weight (M) lb/lbmol 68.64
Compressibility (Z) 0.68
Specific Gravity (SG) 1.578
Critical Pressure Drop (P*) psi 90.0
Flow type Subcritical Subcritical
Full-open Flow (w) lb/h 10,737
Required Relieving Flow lb/h 1,737 1,741
a. Blue = Calculation input
b. Black = Calculated value
c. PSV Plus Vapor Example with Choked Flow

Composition: 40% isobutane, 45% isopentane, 10% n-hexane using the HYSYS SRK
package for physical properties
Normal flowrate: 3,300 lb/h
Control Valve: Cv = 5.5, Cf = 0.75
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M = 68.64
Z = 0.624
Figure 2. Critical vapor control valve case calculated in Aspen HYSYS using PSV Plus equations
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The critical pressure drop may be calculated using (Eq. 1) as

∆𝑃∗ = 0.5(0.75)2 420 = 118.1 psi
The pressure drop across the valve at relieving conditions is only 119.3 psi, so the flow is
critical.
The specific gravity may be calculated using (Eq. 4) as
68.64 520
𝑆𝐺 = × = 1.51
29 355 + 460
The control valve capacity at relief conditions is calculated using (Eq. 2) as
𝑤 = 2.8(0.75)(420)(5.5)√1.51⁄0.624 = 7,546 lb/h

Subtracting the normal flowrate of 3,300 lb/h gives a required relief load of 4,246 lb/h.
Critical Vapor Flow using PSV Plus equations

Calculation
Normal Flow to Process lb/h 3,300 3,300
Control Valve CV (CV) 5.5 5.500
Molecular Weight (M) lb/lbmol 68.64
Compressibility (Z) 0.624
Flow type Critical Critical
Full-open Flow (w) lb/h 7,546
d. PSV Plus Liquid Equations

The critical pressure drop for liquid flow across a control valve is defined as
𝑃𝑣
𝐹𝐹 = 0.96 − 0.28√ (Eq. 5)
𝑃𝑐
∆𝑃∗ = 𝐶𝑓 2 (𝑃1 − 𝐹𝐹 𝑃𝑣 ) (Eq. 6)
where FF is a calculated critical flow parameter, Pv is the vapor pressure / bubble point pressure
of the liquid in psia, and Pc is the critical pressure of the liquid in psia.
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The volumetric capacity of the control valve may be calculated by
∆𝑃𝑚𝑖𝑛
𝑄 = 𝐶𝑣 √ (Eq. 7)
𝑆𝐺
where Pmin is the smaller of the actual pressure drop across the valve and the critical pressure
drop across the valve, SG is the specific gravity of the fluid at upstream conditions relative to
water at 60 F (15.6 C), and Q is the capacity of the control valve in gpm.
The required relief load in gpm may be converted to lb/h:
60 min 1 ft³
𝑤=𝑄× × ×𝜌 (Eq. 8)
1h 7.4805 gal
e. PSV Plus Liquid Example with Unchoked Flow

Composition: 15% propane, 30% isobutane, 30% n-butane, 25% isopentane using the
HYSYS PR package for physical properties
No credit taken for normal flowrate across the valve
Control Valve: Cv = 8, Cf = 0.75
Pc = 562.6 psia
Pv = 216.1 psia
 = 29.95 lb/ft³ hence SG = 29.95/62.3 = 0.4807
The critical pressure drop is calculated from (Eq. 5) and (Eq. 6):
216.1
𝐹𝐹 = 0.96 − 0.28√ = 0.7865
562.6
∆𝑃∗ = 0.752 (275 − 0.7865 × 216.1) = 59 psi
The pressure drop at relief conditions is 51.3 psi, which is less than the critical limit, so flow is
unchoked. The required relief load is calculated from (Eq. 7) and (Eq. 8):
51.3
𝑄 = 8√ = 82.6 gpm
0.4807
60 min 1 ft³
𝑤 = 82.6 gpm × × × 29.95 lb/ft 3 = 19,840 lb/h
1h 7.4805 gal
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Figure 3. Unchoked liquid control valve case calculated in Aspen HYSYS using PSV Plus equations
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Subcritical Liquid Flow using PSV Plus equations

Calculation
Normal Flow to Process lb/h 0 0.0000
Liquid Critical Pressure (Pc) 562.6 psia
Liquid Vapor Pressure (Pv) 216.1 psia
Critical Pressure Drop (P*) psi 59
Flow type Unchoked Subcritical
f. PSV Plus Liquid Example with Choked Flow

Composition: 15% propane, 25% n-butane, 30% n-pentane, 30% n-heptane using the
HYSYS PR package for physical properties
No credit taken for normal flowrate across the valve
Relief pressure: 105 psig set pressure + 10% allowable overpressure = 115.5 psig
Control Valve: Cv = 120, Cf = 0.75
Pc = 583.5 psia
Pv = 247.1 psia
 = 30.85 lb/ft³ hence SG = 30.85/62.3 = 0.495
The critical pressure drop is calculated from (Eq. 5) and (Eq. 6):
247.1
𝐹𝐹 = 0.96 − 0.28√ = 0.778
583.5
∆𝑃∗ = 0.752 (275 − 0.778 × 247.1) = 46.6 psi
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Figure 4. Choked liquid control valve case calculated in Aspen HYSYS using PSV Plus equations
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The pressure drop at relief conditions is 144.8 psi, which is greater than the critical limit, so flow
is choked. The required relief load is calculated from (Eq. 7) and (Eq. 8):
46.6
𝑄 = 120√ = 1164 gpm
0.495
60 min 1 ft³
𝑤 = 1164 gpm × × × 30.85 lb/ft 3 = 288,100 lb/h
1h 7.4805 gal
Critical Liquid Flow using PSV Plus equations

Calculation
Normal Flow to Process lb/h 0 0.0000
Liquid Critical Pressure (Pc) 583.5 psia
Liquid Vapor Pressure (Pv) 247.1 psia
Flow type Choked Critical
2. Heat Exchanger Tube Break

For a heat exchanger tube break scenario, API Standard 521 states that the calculation should
be based on a sharp break in one tube, at the back of the tube sheet, with high pressure fluid
assumed to flow both through the stub in the tubesheet and through the long section of tube. A
calculation basis of flow through two orifices is allowed as a simplifying assumption, because
the resulting relief load is larger than would be calculated based on flow through a long tube. [1]
The tube rupture calculation in the Safety Analysis Environment uses a two-orifice calculation as
described in the literature. [2] [3]
a. Vapor Equations
As with control valves, vapor flow through a tube rupture is subject to a critical flow limit. The
downstream critical limit pressure may be calculated as
𝑘
2 ⁄𝑘−1
𝑃𝑐𝑓𝑟 = 𝑃1 [ ] (Eq. 9)
𝑘+1
where Pcfr is the critical limit pressure in psia, P1 is the high-pressure-side pressure in psia, and
k is the ideal gas specific heat ratio CP/(CP - R) at relief conditions.
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The flow through the rupture is given by
𝑤 = 2407.7 𝐶 𝐴 𝑌√∆𝑃 ∙ 𝜌 (Eq. 10)
where w is the required relief load in lb/h, C is the orifice coefficient, A is the total rupture area in
in², P is the pressure difference between the P1 and the greater of the downstream relief
pressure or Pcfr, and  is the vapor density at upstream conditions in lb/ft³.
For flow from the tube side into the shell side, the orifice coefficient used is typically 0.74 (so the
product with the leading coefficient is 1,781.7), and the expansion coefficient Y may be
calculated as
∆𝑃
𝑌 = 1 − 0.4 (Eq. 11)
𝑃1
For flow from the shell side into the tube side, the orifice coefficient used is typically 0.6 (so the
product with the leading coefficient is 1,444.6), and the expansion coefficient may be calculated
as
∆𝑃
𝑌 = 1 − 0.317 (Eq. 12)
𝑃1
b. Vapor Example with Unchoked Shell-Into-Tube Flow

Composition: 30% propane, 70% n-butane using the HYSYS SRK package for physical
properties
High-pressure side conditions: 110 psia / 300 F
Tubes are 14 ga 7/8” tube with an inner diameter of 0.709 in
Setting up a stream in HYSYS at the high-pressure side conditions will yield the following
properties:
 = 0.7756 lb/ft³
Flashing to relief conditions will yield the following properties:

k = 1.073
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Figure 5. Subcritical vapor exchanger tube rupture case calculated in Aspen HYSYS
The critical flow pressure is calculated using (Eq. 9):

(1.073)
⁄(1.073)−1
2
𝑃𝑐𝑓𝑟 = 110 psia [ ] = 64.9 psia
(1.073) + 1
Since the critical pressure of 64.9 psia is less than the low-pressure side relief pressure of
80.7 psia, flow is not choked and the pressure drop across the break P = 29.3 psi.
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The required relief load may be calculated using (Eq. 10) and (Eq. 12) as
𝜋
𝐴 = 2 (0.709 in)2 = 0.7896 in²
4
29.3
𝑌 = 1 − 0.317 = 0.9156
110
𝑤 = 1444.6(0.7896)(0.9156)√(29.3)(0.7756) = 4,979 lb/h
Table 5. Comparison of Example Calculation and Aspen HYSYS Calculation for Exchanger Tube Rupture with
Subcritical Vapor Flow

Calculation
High Side Pressure (P1) 110 psia 95.3 psig
High Side Temperature F 300 300.0
Tube Inside Diameter in 0.709 0.7090
CP/(CP - R) (k) 1.073 1.073
Mass Density () lb/ft³ 0.7756 0.7756
Critical Pressure (Pcfr) 64.9 psia 50.25 psig
Flow type Subcritical Subcritical
Expansion Factor (Y) 0.9156
c. Vapor Example with Choked Tube-Into-Shell Flow

Composition: 30% propane, 70% n-butane using the HYSYS SRK package for physical
properties
Tubes are 20 ga 1 1/4” tube with an inner diameter of 1.18 in
properties:
 = 2.493 lb/ft³
Flashing to relief conditions will yield the following properties:

k = 1.079
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Figure 6. Critical vapor exchanger tube rupture case calculated in Aspen HYSYS

(1.079)
⁄(1.079)−1
2
𝑃𝑐𝑓𝑟 = 275 psia [ ] = 162.0 psia
(1.079) + 1
Since the critical pressure of 162.0 psia is greater than the low-pressure side relief pressure of
80.7 psia, flow is choked and the pressure drop across the break P = 113.0 psi.
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The required relief load may be calculated using (Eq. 10) and (Eq. 11) as
𝜋
𝐴 = 2 (1.18 in)2 = 2.187 in²
4
113.0
𝑌 = 1 − 0.4 = 0.8356
275
𝑤 = 1781.7(2.187)(0.8356)√(113.0)(2.493) = 54,650 lb/h
Critical Vapor Flow

Calculation
CP/(CP - R) (k) 1.079 1.079
Flow type Critical Critical
d. Liquid Equations
Liquid flow is not checked for choking. The flow through the rupture is given by
𝑤 = 2407.7𝐶𝐴√∆𝑃 ∙ 𝜌 (Eq. 13)
As with vapor cases, for a tube-into-shell break, a value of 0.74 is typically used for the orifice
coefficient, giving a combined leading coefficient of 1781.7. For a shell-into-tube break, a value
of 0.6 is typically used for the orifice coefficient, giving a combined leading coefficient of 1444.6.
e. Liquid Example with Tube-Into-Shell Flow
Composition: 35% n-heptane, 35% n-decane, 30% n-C13 using the HYSYS SRK package for
physical properties
Tubes have an inner diameter of 1.375 in
properties:
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 = 44.3 lb/ft³
Figure 7. Liquid exchanger tube rupture case calculated in Aspen HYSYS
The required relief load may be calculated using (Eq. 13) as

𝜋
𝐴 = 2 (1.375 in)2 = 2.97 in²
4
𝑤 = 1781.7(2.97)√(740 − 455.3)(44.3) = 594,900 lb/h
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Liquid Flow

Calculation
f. Mixed Two-Phase Flow Equations

For two-phase flashing flow, calculation is performed based on a division of the total rupture
area in order to obtain a ratio of mass flows that is equal to the mass fraction vapor of the high-
pressure-side stream flashed isenthalpically to the low-pressure-side relief pressure. The choke
condition is obtained for the vapor and applies to both phases. The downstream critical limit
pressure may be calculated using (Eq. 9):
𝑘⁄
2 𝑘−1
𝑃𝑐𝑓𝑟 = 𝑃1 [ ]
𝑘+1
Here, k is taken at the low-pressure-side relief conditions.

Once the critical limit pressure is obtained, the vapor and liquid properties for calculating the
required relief load are determined at the greater of the critical limit pressure and the low-
pressure-side relief pressure (or high-pressure-side conditions may be used if a vapor phase
exists).
The fraction of the total flow area that is assigned to the vapor phase may be computed as
follows:
𝑁𝑣 = 2404.7𝐶𝑌√∆𝑃 ⋅ 𝜌𝑣 (Eq. 14)
𝑁ℓ = 2404.7𝐶√∆𝑃 ⋅ 𝜌ℓ (Eq. 15)
𝑥 𝑁ℓ
𝑓𝑣 = (Eq. 16)
(1 − 𝑥)𝑁𝑣 + 𝑥 𝑁ℓ
where C is the orifice coefficient, typically 0.6 for shell-into-tube flow or 0.74 for tube-into-shell
flow, Y is the vapor expansion coefficient computed using (Eq. 11) or (Eq. 12) as appropriate,
P is the pressure drop across the tube break subject to the downstream critical limit,  values
are the respective phase densities, and x is the vapor mass fraction at the low-pressure-side
pressure subject to the downstream critical limit.
Then, the required relief load is calculated as the sum of the vapor and liquid flows:
𝑤𝑣 = 𝑓𝑣 𝐴 𝑁𝑣 (Eq. 17)
𝑤ℓ = (1 − 𝑓𝑣 ) 𝐴 𝑁ℓ (Eq. 18)
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𝑤 = 𝑤𝑣 + 𝑤ℓ (Eq. 19)
Figure 8. Mixed phase, subcritical exchanger tube rupture case calculated in Aspen HYSYS
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Figure 9. Mixed phase, critical exchanger tube rupture case calculated in Aspen HYSYS
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g. Mixed Phase Example with Unchoked Tube-Into-Shell Flow

Composition: 35% propane, 40% n-heptane, 25% CC6= using the HYSYS SRK package for
physical properties
Setting up a stream in HYSYS at the high-pressure side conditions and performing an

isenthalpic flash to relief pressure will yield the following properties:
T = 333.8 F
k = 1.059

(1.059)
⁄(1.059)−1
2
𝑃𝑐𝑓𝑟 = 470 psia [ ] = 278.9 psia
(1.059) + 1
Since the critical pressure of 278.9 psia is less than the low-pressure side relief pressure of
289.7 psia, flow is not choked and the pressure drop across the break P = 180.3 psi. Liquid
and vapor properties may be obtained in HYSYS at the high side pressure using the previously-
flashed stream, yielding:
𝜌ℓ = 28.74 lb/ft³
𝜌𝑣 = 4.529 lb/ft³
The vapor fraction at relief conditions is:

x = 0.2588
The required relief load may be calculated using (Eq. 12) and (Eq. 14) through (Eq. 19):
𝜋
𝐴 = 2 (1.18 in)2 = 2.187 in²
4
180.3
𝑌 = 1 − 0.4 = 0.8466
470
𝑁𝑣 = 1781.7(0.8466)√(180.3)(4.529) = 43103
𝑁ℓ = 1781.7√(180.3)(28.74) = 128255
(0.2588)(128255)
𝑓𝑣 = = 0.5096
(1 − 0.2588)(43103) + (0.2588)(128255)
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𝑤𝑣 = (0.5096)(2.187)(43103) = 48,040 lb/h

𝑤ℓ = (1 − 0.5096)(2.187)(128255) = 137,600 lb/h
𝑤ℓ = (1 − 0.5096)(2.187)(128255) = 137,600 lb/h
𝑤 = 𝑤𝑣 + 𝑤ℓ = 185,600 lb/h
Subcritical Mixed Phase Flow

Calculation
CP/(CP - R) (k) 1.059 1.059
Vapor Mass Density (𝜌𝑣 ) lb/ft³ 4.529 4.529
Liquid Mass Density (𝜌ℓ ) lb/ft³ 28.74 28.74
Flow type Subcritical
Mass Fraction Vapor (x) 0.2588 0.2588
h. Mixed Phase Example with Choked Shell-Into-Tube Flow

Composition: 35% propane, 40% n-heptane, 25% CC6= using the HYSYS SRK package for
physical properties
Setting up a stream in HYSYS at high-pressure side conditions and performing an isenthalpic

flash to relief pressure will yield the following properties:
k = 1.061

(1.061)
⁄(1.061)−1
2
𝑃𝑐𝑓𝑟 = 470 psia [ ] = 278.7 psia
(1.061) + 1
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Since the critical pressure of 278.7 psia exceeds the low-pressure side relief pressure of
179.7 psia, flow is choked and the pressure drop across the break P = 191.3 psi. Liquid and
vapor properties may be obtained in HYSYS at the high side pressure using the previously-
flashed stream, yielding:
𝜌ℓ = 28.74 lb/ft³
𝜌𝑣 = 4.529 lb/ft³
The vapor fraction at the choke condition is:

x = 0.2718
The required relief load may be calculated using (Eq. 11) and (Eq. 14) through (Eq. 19):
𝜋
𝐴 = 2 (1.18 in)2 = 2.187 in²
4
191.3
𝑌 = 1 − 0.317 = 0.8710
470
𝑁𝑣 = 1444.6(0.8710)√(191.3)(4.529) = 37036
𝑁ℓ = 1444.6√(191.3)(28.74) = 107114
(0.2718)(107114)
𝑓𝑣 = = 0.5191
(1 − 0.2718)(37036) + (0.2718)(107114)
𝑤𝑣 = (0.5191)(2.187)(37036) = 42,050 lb/h
𝑤ℓ = (1 − 0.5191)(2.187)(107114) = 112,700 lb/h
𝑤 = 𝑤𝑣 + 𝑤ℓ = 154,800 lb/h
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Critical Mixed Phase Flow

Calculation
CP/(CP - R) (k) 1.061 1.061
Vapor Mass Density (𝜌𝑣 ) lb/ft³ 4.529 4.529
Liquid Mass Density (𝜌ℓ ) lb/ft³ 28.74 28.74
Flow type Critical Choked Flow
Mass Fraction Vapor (x) 0.2718 0.2717
3. Hydraulic Expansion
a. Equations
For a scenario where heat input causes hydraulic expansion in blocked-in, liquid-full equipment
or process piping, API Standard 521 gives two equations for calculating the required relief load,
one for U.S. customary units and one for SI units. [1] These equations may be combined and
written as
𝛼𝑉 𝜙
𝑞= (Eq. 20)
𝑁 𝑆𝐺 𝐶𝑃
where q is the volumetric required relief load in m³/s or gpm, N is a dimensional constant with a
value of 1000 for SI units or 500 for U.S. customary units, V is the cubic expansion coefficient
in 1/K or 1/R,  is the total heat transfer rate in W or BTU/h, SG is the specific gravity of the fluid
referenced to water at 60 F or 15.6 C (a reference density of 998.9 kg/m³ or 62.3 lb/ft³), and CP
is the fluid heat capacity in J/kg-K or BTU/lb-R.
b. Example
f = 500,000 kcal/h = 2,093,400 kJ/h = 581.5 kW
aV = 0.0085 1/K
SG = 0.63
CP = 0.591 kcal/kg-K = 2.474 kJ/kg-K
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Figure 10. Hydraulic expansion case calculated in Aspen HYSYS
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The required relief load is calculated using (Eq. 20), and converted to a mass flow rate:
(0.0085)(581,500)
𝑞= = 0.00317 m3 /s
1000(0.63)(2,474)
3600 s
𝑤 = 0.00317 m³/s × × (0.63)(998.9 kg/m3 ) = 7182 kg/h
1h
Table 10. Comparison of Example Calculation and Aspen HYSYS Calculation for Hydraulic Expansion

Calculation
Expansion Coefficient (V) 1/K 0.0085 0.0085
Heat Input Rate () 581,500 W 500,000 kcal/h
Specific Gravity (SG) 0.63 0.6299
Mass Heat Capacity (CP) 2,474 J/kg-K 0.5910 kcal/kg-K
4. Fire
a. Wetted Fire Equations
The required relief load due to vaporization of liquid inventory is calculated using equations
obtained from API Standard 521. [1]
The required relief load is calculated using the following equations:
𝑄 = 𝐶𝐷𝐹 𝐹 𝐴𝑤𝑠 0.82 (Eq. 21)
where Q is the rate at which heat is added to the vessel contents in W; CDF is a constant to
account for the presence or absence of adequate draining and firefighting, with a value of
43,200 when adequate drainage and firefighting are present or 70,900 when they are not; F is
an environment factor to account for the presence of fireproof insulation, with a value of 1.0 for a
vessel without fireproof insulation; Aws is the exposed wetted surface area of the vessel, subject
to certain conditions, in m².
Per the standard, for horizontal and vertical vessels, only the portion of the liquid inventory
within 7.6 m of grade should be considered. For spherical vessels, the portion of the liquid
inventory within 7.6 m of grade or up to the maximum horizontal diameter, whichever is greater,
should be considered.
𝑤 = 3.6 𝑄/𝜆 (Eq. 22)
where w is the required relief load in kg/h and l is the latent heat of the vessel contents at
appropriate relieving conditions in kJ/kg
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Figure 11. External fire case with a wetted vertical vessel calculated in Aspen HYSYS
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b. Wetted Fire Example with a Vertical Vessel

Composition: 50% propane, 50% isobutane using the HYSYS PR package for physical
properties
Normal operating conditions: 1000 kPaa, 85% vapor
Relief pressure: 12 barg set pressure + 21% allowable overpressure = 14.52 barg
Vessel: Vertical with exposed bottom head, 3.5 m diameter, 8 m T/T height, with 2:1
ellipsoidal heads; 0 m above grade; normal liquid level is 3 m
Additional fire area: 10% to allow for process piping
Insulation: No fireproof insulation is present
Drainage and firefighting: Adequate drainage and firefighting are present
Latent heat: The latent heat of the liquid at relieving conditions is estimated to be 280.8 kJ/kg
No correction needs to be made to the portion of liquid inventory that is considered, as the
normal liquid level is less than 7.6 m above grade. The wetted surface area is computed as
follows:
𝐴𝑠ℎ𝑒𝑙𝑙 = 𝜋 𝐷 𝐿𝐿 = 32.99 m²
𝐴ℎ𝑒𝑎𝑑 = 1.084 𝐷2 = 13.28 m²
𝐴𝑤𝑠 = 1.10 × (𝐴𝑠ℎ𝑒𝑙𝑙 + 𝐴ℎ𝑒𝑎𝑑 ) = 50.9 m²
The required relief load is calculated using (Eq. 21) and (Eq. 22):
𝑄 = (43200)(1.0)(50.9)0.82 = 1,084,000 W
(1,084,000)
𝑤 = 3.6 = 13,900 kg/h
280.8
Table 11. Comparison of Example Calculation and Aspen HYSYS Calculation for External Fire on a Vertical
Wetted Vessel

Calculation
Vessel Type Vertical Vertical
Bottom Head Included? Yes Yes
Vessel Diameter (D) m 3.5 3.500
Vessel T/T Length (L) m 8.0 8.000
Vessel Liquid Level (LL) m 3.0 3.000
Vessel Elevation Above Grade m 0.0 0.000
Additional Area 10% 10.00%
Environment Factor (F) 1.0 1.000
Latent Heat () kJ/kg 280.8 280.8
Adequate drainage and firefighting present? Yes Yes
Heat Input Area (Aws) m² 50.9 50.89
Heat Input (Q) 1,084,000 W 3,901,000 kJ/h
Required Relieving Flow kg/h 13,900 13,890
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Figure 12. External fire case with a wetted horizontal vessel calculated in Aspen HYSYS
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c. Wetted Fire Example with a Horizontal Vessel

properties
Vessel: Horizontal, 3.5 m diameter, 8 m T/T length, with 2:1 ellipsoidal heads; 0 m above
grade; normal liquid level is 1.5 m
Drainage and firefighting: Adequate drainage and firefighting are not present
The fraction of the total area of the horizontal shell that is wetted may be computed by
𝑟−ℎ
cos 𝜃 =
𝑟
𝜃 = 1.427
2𝜃 𝜃
𝑓𝑤𝑠 = = = 0.454
2𝜋 𝜋
𝐴𝑠ℎ𝑒𝑙𝑙 = 𝑓𝑤𝑠 𝜋 𝐷 𝐿 = 39.97 m²
𝐵 = √1 + 12(ℎ⁄𝐷 − 0.5)2 = 1.030

𝜋𝐷 2 3.464(ℎ⁄𝐷 − 0.5) + 𝐵
𝐴ℎ𝑒𝑎𝑑 = 2 × [𝐵(ℎ⁄𝐷 − 0.5) + 1 + 0.2887 ln ( )] = 11.89 m²
8 2 − √3
𝐴𝑤𝑠 = 1.10 × (𝐴𝑠ℎ𝑒𝑙𝑙 + 𝐴ℎ𝑒𝑎𝑑 ) = 57.0 m²
The required relief load is calculated using (Eq. 21) and (Eq. 22):
𝑄 = (70900)(1.0)(57.0)0.82 = 1,952,000 W
(1,952,000)
𝑤 = 3.6 = 25,030 kg/h
280.8
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Table 12. Comparison of Example Calculation and Aspen HYSYS Calculation for External Fire on a Horizontal
Wetted Vessel

Calculation
Vessel Type Horizontal Horizontal
Adequate drainage and firefighting present? No No
Heat Input (Q) 1,952,000 W 6,924,000 kJ/h
d. Wetted Fire Example with a Spherical Vessel

properties
Vessel: Spherical, 5 m diameter
Drainage and firefighting: Adequate drainage and firefighting are present
Five variations will be considered: (i) elevation of 6 m, liquid level of 2 m; (ii) elevation of 6 m,
liquid level of 3 m; (iii) elevation of 5 m, liquid level of 2 m; (iv) elevation of 5 m, liquid level of
3 m; (v) elevation of 4 m, liquid level of 3 m.
The wetted area exposed to heat input will be calculated using the following equation:
𝐴𝑠𝑝ℎ𝑒𝑟𝑒 = 𝜋 𝐷 ℎ (Eq. 23)
The appropriate value for h depends on the variation of the example that we consider. In
case (i), the liquid level is above 7.6 m above grade, but below the equator of the vessel, so the
full level of 2 m is considered. In case (ii), the liquid level is above 7.6 m above grade and
above the equator of the vessel; the equator is higher, so that level of 2.5 m is used. In case
(iii), the liquid level is not above 7.6 m above grade nor above the equator of the vessel, so the
full level of 2 m is considered. In case (iv), the liquid level is above 7.6 m above grade and
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above the equator of the vessel; 7.6 m above grade is higher, so a level of (7.6 m – 5 m = 2.5
m) is used. In case (v), the liquid level is below 7.6 m above grade and below the equator of the
vessel, so the full level of 3 m is considered.
Figure 13. External fire case with a wetted spherical vessel calculated in Aspen HYSYS
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The resulting wetted areas are:

i 𝐴𝑤𝑠 = 𝜋(5)(2) = 31.4 m²
ii 𝐴𝑤𝑠 = 𝜋(5)(2.5) = 39.3 m²
iii 𝐴𝑤𝑠 = 𝜋(5)(2) = 31.4 m²
iv 𝐴𝑤𝑠 = 𝜋(5)(2.6) = 40.8 m²
v 𝐴𝑤𝑠 = 𝜋(5)(3) = 47.1 m²
Then, the required relief loads are:

i 𝑤 = 43200(31.4)0.82⁄280.8 × 3.6 = 9,351 kg/h
ii 𝑤 = 43200(39.3)0.82⁄280.8 × 3.6 = 11,240 kg/h
iii 𝑤 = 43200(31.4)0.82⁄280.8 × 3.6 = 9,351 kg/h
iv 𝑤 = 43200(40.8)0.82⁄280.8 × 3.6 = 11,590 kg/h
v 𝑤 = 43200(47.1)0.82⁄280.8 × 3.6 = 13,030 kg/h
The results calculated above for case (iii) are compared to results obtained in Aspen HYSYS in
Table 13.
Table 13. Comparison of Example Calculation and Aspen HYSYS Calculation for External Fire on a Spherical
Wetted Vessel

Calculation
Vessel Type Spherical Spherical
Adequate drainage and firefighting present? Yes Yes
Heat Input (Q) 729,400 W 2,626,000 kJ/h
e. Unwetted Fire Equations

The required relief load for a vessel filled with vapor (or vapor-like supercritical fluid) exposed to
a fire are obtained from API Standard 521. [1]
The required relief load is calculated using the following equations:
𝑘+1
2 𝑘−1
𝐶 = 0.0395√𝑘 (
(Eq. 24)
)
𝑘+1
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where k is the ideal gas specific heat ratio CP/(CP – R)
𝑝1
𝑇 𝑇1 = (Eq. 25)
𝑝𝑛 𝑛
where T1 is the temperature at the upstream relieving pressure in K, Tn is the normal operating
temperature in K, and p1/pn is the ratio of relief to normal operating pressure in kPaa.
0.2772 (𝑇𝑤 − 𝑇1 )1.25

𝐹′ = [ ] (Eq. 26)
𝐶 𝐾𝐷 𝑇1 0.6506
where Tw is the maximum wall temperature of the vessel in K and KD is the coefficient of
discharge of the relief valve (a value of 0.975 is typically used for preliminary design
calculations).
A minimum value of 182 should be used for F’.
𝐴′(𝑇𝑤 − 𝑇1 )1.25
𝑤 = 0.2772√𝑀 ⋅ 𝑝1 [ ] (Eq. 27)
𝑇11.1506
where w is the required relief load in kg/h, M is the molecular weight of the fluid, and A’ is the
vessel area exposed to fire, which is calculated using the same method as the wetted area for a
liquid-full vessel exposed to fire.
f. Unwetted Fire Example

Composition: 100% water using the HYSYS NBS Steam package for physical properties
Normal operating conditions: 2600 kPaa / 226.1 C
Relief pressure: 25.17 barg set pressure + 10% overpressure = 27.7 barg = 2870 kPaa
Maximum wall temperature: 866.5 K (from 1100 F)
Vessel: Horizontal, 1.016 m diameter, 3 m T/T length, with 2:1 ellipsoidal heads; 0 m above
grade
Relief temperature is calculated using (Eq. 25):

2870
𝑇1 = 499.25 = 551.1 K
2600
Flashing the contents at relief pressure and temperature in HYSYS yields the following
properties:
k = 1.210
Then, the required relief load is calculated using (Eq. 24), (Eq. 26), and (Eq. 27):
1.210+1
2 1.210−1
𝐶 = 0.0395√(1.210) ( ) = 0.0257
1.210 + 1
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0.2772 (866.5 − 551.1)1.25

𝐹′ = [ ] = 242.1
(0.0257)(0.975) 551.10.6506
This value is greater than 182, so no modification is needed to proceed.
Figure 14. External fire case with an unwetted horizontal vessel calculated in Aspen HYSYS
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𝐴𝑠ℎ𝑒𝑙𝑙 = 𝜋𝐷𝐿 = 9.58 m²

𝐴ℎ𝑒𝑎𝑑𝑠 = 2 × 1.084 𝐷 2 = 2.24 m²
𝐴′ = 1.15 × (𝐴𝑠ℎ𝑒𝑙𝑙 + 𝐴ℎ𝑒𝑎𝑑𝑠 ) = 13.6 m²
13.6(866.5 − 551.1)1.25
𝑤 = 0.2772√(18.02)(1600) [ ] = 799.1 kg/h
551.11.1506
Table 14. Comparison of Example Calculation and Aspen HYSYS Calculation for External Fire on a Horizontal
Unwetted Vessel

Calculation
Maximum Wall Temperature 866.5 K 593.3 C
Operating Temperature C 226.1
Operating Pressure kPaa 2600
Vessel Type Horizontal Horizontal
Heat Input Area (A’) m² 13.6 13.59
C 0.0257
F’ 242.1
Required Relieving Flow kg/h 799.1 798.0
REFERENCES
[1] American Petroleum Institute, API Standard 521 6th Ed.: Pressure-relieving and
Depressuring Systems, Washington, DC: API Publishing Services, 2014.
[2] W. Y. Wong, "PRV sizing for exchanger tube rupture," Hydrocarbon Processing, pp. 59-64,
February 1992.
[3] W. Y. Wong, "Correction to 'PRV sizing for exchanger tube rupture'," Hydrocarbon
Processing, p. 44, May 1992.
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aspenONE Engineering Safety Analysis Environment

Equations and example benchmark calculations for emergency

reserved. All other trademarks are property of their respective owners.

EQUATIONS AND EXAMPLE BENCHMARK CALCULATIONS FOR

a. PSV Plus Vapor equations

∆𝑃∗ = 0.5𝐶𝑓 2 𝑃1 (Eq. 1)

parameter of the control valve.

𝑤 = 2.8𝐶𝑓 𝑃1 𝐶𝑣 √𝑆𝐺 ⁄𝑍 (Eq. 2)

Otherwise, the mass flow rate through the valve is given by

∆𝑃∗ (𝑃𝑟 + 𝑃1 )𝑆𝐺

where M is the molecular weight and Tr is the upstream temperature in °F.

b. PSV Plus Vapor Example with Unchoked Flow

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The critical pressure drop may be calculated using (Eq. 1) as

19.3(286 + 14.7 + 320)1.578

Variable Units Example Aspen HYSYS

c. PSV Plus Vapor Example with Choked Flow

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The critical pressure drop may be calculated using (Eq. 1) as

𝑤 = 2.8(0.75)(420)(5.5)√1.51⁄0.624 = 7,546 lb/h

Variable Units Example Aspen HYSYS

d. PSV Plus Liquid Equations

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The volumetric capacity of the control valve may be calculated by

e. PSV Plus Liquid Example with Unchoked Flow

∆𝑃∗ = 0.752 (275 − 0.7865 × 216.1) = 59 psi

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Variable Units Example Aspen HYSYS

f. PSV Plus Liquid Example with Choked Flow

∆𝑃∗ = 0.752 (275 − 0.778 × 247.1) = 46.6 psi

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Variable Units Example Aspen HYSYS

2. Heat Exchanger Tube Break

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The flow through the rupture is given by

𝑤 = 2407.7 𝐶 𝐴 𝑌√∆𝑃 ∙ 𝜌 (Eq. 10)

b. Vapor Example with Unchoked Shell-Into-Tube Flow

Flashing to relief conditions will yield the following properties:

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The critical flow pressure is calculated using (Eq. 9):

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Variable Units Example Aspen HYSYS

c. Vapor Example with Choked Tube-Into-Shell Flow

Flashing to relief conditions will yield the following properties:

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The critical flow pressure is calculated using (Eq. 9):

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Variable Units Example Aspen HYSYS

𝑤 = 2407.7𝐶𝐴√∆𝑃 ∙ 𝜌 (Eq. 13)

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Figure 7. Liquid exchanger tube rupture case calculated in Aspen HYSYS

The required relief load may be calculated using (Eq. 13) as

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Variable Units Example Aspen HYSYS

f. Mixed Two-Phase Flow Equations

Here, k is taken at the low-pressure-side relief conditions.

𝑁𝑣 = 2404.7𝐶𝑌√∆𝑃 ⋅ 𝜌𝑣 (Eq. 14)

𝑁ℓ = 2404.7𝐶√∆𝑃 ⋅ 𝜌ℓ (Eq. 15)

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